CN1210458C - Nonwoven backing and carpet comprising same - Google Patents

Nonwoven backing and carpet comprising same Download PDF

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Publication number
CN1210458C
CN1210458C CNB998102121A CN99810212A CN1210458C CN 1210458 C CN1210458 C CN 1210458C CN B998102121 A CNB998102121 A CN B998102121A CN 99810212 A CN99810212 A CN 99810212A CN 1210458 C CN1210458 C CN 1210458C
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CN
China
Prior art keywords
layer
end liner
fiber
binder polymer
polymer
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Expired - Fee Related
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CNB998102121A
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Chinese (zh)
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CN1319149A (en
Inventor
P·T·库仑
S·T·约翰逊三世
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Freudenberg Performance Materials BV
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Colbond BV
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Application filed by Colbond BV filed Critical Colbond BV
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Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/58Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
    • D04H1/587Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives characterised by the bonding agents used
    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/541Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres
    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/542Adhesive fibres
    • DTEXTILES; PAPER
    • D06TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06NWALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N7/00Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
    • D06N7/0063Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf
    • D06N7/0068Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by the primary backing or the fibrous top layer
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02Synthetic macromolecular fibres
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2471/00Floor coverings
    • B32B2471/02Carpets
    • DTEXTILES; PAPER
    • D06TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06NWALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2201/00Chemical constitution of the fibres, threads or yarns
    • D06N2201/02Synthetic macromolecular fibres
    • DTEXTILES; PAPER
    • D06TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06NWALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2201/00Chemical constitution of the fibres, threads or yarns
    • D06N2201/02Synthetic macromolecular fibres
    • D06N2201/0254Polyolefin fibres
    • DTEXTILES; PAPER
    • D06TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06NWALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2201/00Chemical constitution of the fibres, threads or yarns
    • D06N2201/10Conjugate fibres, e.g. core-sheath, side-by-side
    • DTEXTILES; PAPER
    • D06TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06NWALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2203/00Macromolecular materials of the coating layers
    • D06N2203/06Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • D06N2203/065Polyamides
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/23907Pile or nap type surface or component
    • Y10T428/23979Particular backing structure or composition
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/30Woven fabric [i.e., woven strand or strip material]
    • Y10T442/3472Woven fabric including an additional woven fabric layer
    • Y10T442/348Mechanically needled or hydroentangled
    • Y10T442/3496Coated, impregnated, or autogenously bonded
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/30Woven fabric [i.e., woven strand or strip material]
    • Y10T442/3472Woven fabric including an additional woven fabric layer
    • Y10T442/3504Woven fabric layers comprise chemically different strand material
    • Y10T442/3512Three or more fabric layers
    • Y10T442/352One of which is a nonwoven fabric layer
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/30Woven fabric [i.e., woven strand or strip material]
    • Y10T442/3472Woven fabric including an additional woven fabric layer
    • Y10T442/3528Three or more fabric layers
    • Y10T442/3594Woven fabric layers impregnated with a thermoplastic resin [e.g., vinyl polymer, etc.]
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/30Woven fabric [i.e., woven strand or strip material]
    • Y10T442/3472Woven fabric including an additional woven fabric layer
    • Y10T442/3602Three or more distinct layers
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/30Woven fabric [i.e., woven strand or strip material]
    • Y10T442/3472Woven fabric including an additional woven fabric layer
    • Y10T442/3602Three or more distinct layers
    • Y10T442/3667Composite consisting of at least two woven fabrics bonded by an interposed adhesive layer [but not two woven fabrics bonded together by an impregnation which penetrates through the thickness of at least one of the woven fabric layers]
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/30Woven fabric [i.e., woven strand or strip material]
    • Y10T442/3707Woven fabric including a nonwoven fabric layer other than paper
    • Y10T442/3724Needled
    • Y10T442/3764Coated, impregnated, or autogenously bonded
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/30Woven fabric [i.e., woven strand or strip material]
    • Y10T442/3707Woven fabric including a nonwoven fabric layer other than paper
    • Y10T442/378Coated, impregnated, or autogenously bonded

Abstract

The invention pertains to a nonwoven primary carpet backing comprising thermoplastic polymer filaments or fibres bonded by means of a binder polymer, wherein the backing comprises at least a distinguishable thermoplastic woven layer, a distinguishable thermoplastic continuous layer, or a distinguishable nonwoven layer also comprising filaments or fibres bonded by means of a binder polymer, which layer reduces the delamination strength of the backing, measured in accordance with DIN 54310, by at least 30 % and preferably by at least 50 %, with respect to the same backing without the said distinguishable layer. Although the breaking strength of the untufted backing according to the invention is lower than that of untufted prior art backings, the tufted backing according to the invention actually has a higher breaking strength and elongation than tufted prior art backings.

Description

Non-woven end liner and comprise the carpet of this end liner
The present invention relates to comprise through the bonding filament thermoplastic polymer of binder polymer or the non-woven carpet end liner of fiber.
Comprise manufacturing, come out for many years, for example can from United States Patent (USP) 4842915, know through the non-woven carpet end liner of bonding long filament of for example thermoplastic polymer adhesive or fiber.This patent disclosure relates to the nonwoven fabric that is made of polyester matrix type long filament, and this fabric is suitable for the synthetic tuft base cloth make carpet and can be strengthened by the adhesive component with long filament, fiber, powder and/or the fine particle form of softness.This adhesive component is made of than the polypropylene of low 90 ℃ of polyester matrix type long filament or fiber melting range at least melting range.
For many years, in order to satisfy the more and more stricter requirement of manufacturer and consumer, the non-woven carpet end liner constantly is improved.Important improvement is: fracture strength and elongation at break behind the raising synthetic tuft, tear resistance after improving synthetic tuft and being coated with, the general outward appearance that makes carpet of improving, can repair the defective that produces in the synthetic tuft process and make and be easy to synthetic tuft, promptly in the synthetic tuft process, produce the resistance of lower opposing acupuncture, reduce inclined to one side pin, avoid crude back stitch, the noise that increases looped pile bunch and reduce the synthetic tuft process.
An object of the present invention is to reach described improvement.This purpose realizes in the carpet underlay described in first section, wherein end liner comprises the recognizable thermoplasticity weaving layer of one deck at least, one deck thermoplasticity pantostrat or one deck comprise through the bonding long filament of binder polymer or the non-woven layer of fiber, this can distinguish that layer works to reduce the end liner delamination strength, the delamination strength that records according to DIN 54310 reduces at least 30% with respect to not containing the described similar end liner of layer of distinguishing, and preferably at least 50%.
In general, because the acanthopore of synthetic tuft pin can cause break and/or damage, therefore, synthetic tuft can reduce the fracture strength (high initial collapse intensity) of non-woven end liner.And have been found that by (replenish or additional) one deck and can distinguish that layer reaches the reduction of delamination strength that also can reduce the tensile break strength of end liner significantly, the reduction of this intensity looks shortcoming seemingly.Yet this predetermined fracture strength according to the present invention reduces the delamination strength of reduction end liner (promptly by) and has suppressed the fracture strength that causes because of synthetic tuft and the decline of elongation at break.Though the fracture strength according to non-synthetic tuft end liner of the present invention is lower than the non-synthetic tuft end liner of prior art, in fact synthetic tuft end liner according to the present invention has fracture strength and the elongation at break high than prior art synthetic tuft end liner.This phenomenon will be illustrated and confirm by following examples.
Play a part to reduce delamination strength (for example long filament or fiber have than high fluidity and/or low with other layer adhesiveness) on the one hand, the opposing party should have enough laminated cohesive force again so that stand the layer distinguished of (violent) carrying and processing, it can be many different forms, for example dry-laying supatex fabric, wet-laid non-woven fabric or melt-blown fabric.Other example is Woven fabric and pantostrat such as film or paper tinsel.Yet the hot method or the chemical method spunbonded non-woven fabrics that also can carry out acupuncture or Hydroentangled (hydroentangled) are preferred.
Being noted that European patent application EP 822283 has related to comprises the skin/core bi-component (a) and (b) spun-bonded fibre net of two class long filaments, and wherein core component is that fusing point is higher than the polyethylene terephthalate as the adhesive polymer of skin component.Skin polymer (a) class long filament is 1 with (b) weight ratio of class long filament: 3-1: 10.On the fiber web cross section, (a) the class long filament and (b) weight ratio of class long filament between 15-70%, do not wait.Back one ratio does not have significant change on fiber web entire cross section plane, does not perhaps have recognizable boundary, has so just avoided delamination.Therefore, this technology is to promote the technology of delamination to run in the opposite direction with requirement of the present invention.
Japanese patent application JP 04-352861 has related to the supatex fabric that is made of composite long fiber A and composite long fiber B, wherein composite long fiber A comprises the polymer a2 that polymer a1 and fusing point are higher than at least 30 ℃ of a1, and composite long fiber B comprises the polymer b2 that polymer b1 and fusing point are higher than at least 30 ℃ of b1.And the fusing point of polymer b1 is higher than at least 20 ℃ of a1.This fabric constitutes by four layers, a ground floor fibre-bearing A, in the second layer fiber A more than fiber B, in the 3rd layer fiber B more than fiber A, the 4th layer of fibre-bearing B.The change in concentration of fiber A and fiber B is the continuous tangible boundary line that do not have, and therefore delamination can not take place.
United States Patent (USP) 3940302 discloses a kind of nonwoven web of making the knotted rug end liner that is suitable for, this fiber web comprises with the polypropylene to be core and to be the bicomponent filament of skin material with copolyamide (" can become in high-pressure saturated steam is adhesive, and core component is unaffected basically under this pressure ") with polypropylene monofilament (homofilaments).Doubling vertically embeds in the fiber web along fiber web.In a preferred embodiment, the concentration of bicomponent filament at least one surperficial thin layer of product is high in this product center, to improve the absorption of end liner surface to dyestuff.
Japan Patent JP 09291457 has related to a kind of laminate that comprises the multi-layer fiber layer, and wherein fibrage comprises paracytic type or the skin/core pattern composite long fiber that is had polymer (being high density polyethylene (HDPE) and the high density poly propylene) formation of different melting points by two classes.The content of high density polyethylene (HDPE) in every layer of fibrage is different.This laminate has fabulous bulkiness, feel and tensile strength.
Japan Patent JP 06128855 discloses a kind of three-decker supatex fabric that comprises top layer, intermediate layer and backing layer.Top layer and backing layer are to be made of the conjugated type long fiber that contains thermoplastic polymer components A and the thermoplastic polymer components B compatible with A.This long fiber is bonding with the fusion of component A and B component.The intermediate layer only comprises fiber A that is made of A and the fiber B that only is made of B, and wherein these fibers thread form by long stapled branchs of conjugated type.Fiber A and fiber B tangle, and do not have fusion basically.
United States Patent (USP) 5660910 discloses a kind of comprise continuous substrate filament of putting random shop and the adhesive nonwoven composite fiber web that strengthens long filament continuously, wherein the average linear density of every continuous substrate filament was lower than for 25 dawn, the average linear density that strengthens long filament surpassed for 20 dawn, and surpassed at least 10 dawn of average linear density of every described substrate filament; Wherein said continuous substrate filament is to be bonded together at least in part and to form described fiber web, and the described continuous enhancing long filament in the described fiber web basically not with fiber web in other long filament bonding (emesh), therefore, when fiber web carries out tear test according to ASTM D2261-83, can pull out in the fiber web and to strengthen long filament more than three and reach more than 1 centimetre.Fabric according to embodiment in the United States Patent (USP) 5660910, this fabric comprises long filament that as the matrix yarn every was 13.5 dawn and as the nylon 66 or the polyethylene terephthalate monofilament at single 300 dawn that strengthen yarn, this fabric through synthetic tuft and molded after, have high tearing strength and have the enhancing of a pulling out characteristic.
In framework of the present invention, comprise and two-layerly distinguish that the carpet underlay of layer is a kind of feasible selection, be that preferably therefore, end liner comprises at least three layers can distinguish layer but end liner is embedded with the layer (internal layer) that reduces the delamination strength effect.In this structure, skin can move with respect to another layer (partly), helps to keep the synthetic tuft yarn like this and helps to reach desired stability and other physical property of end liner.
Every layer comprise (thermoplasticity) binder polymer and filament thermoplastic polymer or fiber and also be preferred through the end liner of heat bonding, wherein concentration and/or the tack temperature of binder polymer in working the layer that reduces the delamination strength effect hangs down at least 20% than binder polymer in other layer, preferably at least 30% and/or high 4 ℃, preferably at least 6 ℃.By reducing bondability, delamination strength is reduced effectively, because long filament or fiber in described layer have bigger mobility, so the maintenance of synthetic tuft yarn (being also referred to as " looped pile bunch " or " looped pile maintenance ") has obtained further enhancing.
On the other hand, carefully select binder polymer, the inconsistent binder polymer of binder polymer in selection and the adjacent layer can reduce the cohesiveness to described layer, thereby obtains lower delamination strength.
The fusion of binder polymer or softening temperature are preferably lower than the fusion of long filament or fiber or softening temperature 15-20 ℃, but concerning some polyblend, littler temperature difference may be suitable or or even necessary.
When binder polymer is the part (binder polymer preferably is constituted to the outer surface part of the youthful and the elderly's silk or fiber) of long filament or fiber, this moment, used noun long filament or fiber were meant bicomponent filament or fiber, when long filament or fiber lay down row, binder polymer is to be evenly distributed in the whole also not bonding supatex fabric.Because in fact therefore the even distribution of binder polymer in supatex fabric all can have adhesive to exist in all contact positions of long filament or fiber.Therefore, a large amount of bounding points is arranged, in addition, in the heat bonding process, can also guarantee to each contact point effective supply adhesive.
Bicomponent fiber and long filament or core/integumentary pattern fiber or bilateral fibre are specially adapted to according in the supatex fabric of the present invention.
Another kind of well-adapted method of adding adhesive to thermoplastic filament or fiber be utilize fully by or most of " the bonding long filament of using " or " binder fibre of making by binder polymer ".These are bonding puts together with long filament or binder fibre and other long filament or fiber lay down, is evenly distributed in result in the whole also not bonding supatex fabric so also obtained adhesive.This supatex fabric is also referred to as " two filament nonwoven fabric " sometimes.
Just in this point, the present invention to the form of above-mentioned binder polymer without limits.Adhesive also can different shape for example powdery, emulsion or add to not in binder filaments or the fiber with fine strip body.
Very suitablely make the polymer of binder polymer in the supatex fabric of the present invention and the example of co-polymer is one or more mixture of polymers in polyamide 6, copolyamide, copolyester, polypropylene, co-polypropylene, polyethylene and these polymer.The example of the another kind of material that is suitable for is a polybutylene terephthalate (PBT).Adhesive also can add by morphon, and this monomer is to solidify (being polymerization) in adhesion process.
In other polymer, polyester is very suitable thermoplastic filament or the fiber done.More suitable material also comprises (but not limited) polyamide 6, polyamide 46, polyamide 66, copolyamide and copolyesters.
If working the layer that reduces delamination strength is non-woven fabric layer, binder polymer preferably is lower than 20: 80 with the volume ratio of the polymer that forms long filament or fiber so, more preferably less than 15: 85.In other non-woven fabric layer, described ratio is preferably 20: 80-50: 50, more preferably 20: 80-35: 65.
The line density of long filament or fiber is the 5-20 dtex.When line density was lower than about 1 dtex, then non-woven fabric material can be quite closely when higher basis weights (particularly), and this can more fragile end liner also can increase the number of inclined to one side pin in the synthetic tuft process.When line density surpassed about 25 dtexs, then supatex fabric can be " pine " when basic weight (especially low) very, and looped pile keeps and can descend.
According to total basic weight of carpet underlay of the present invention preferably be at least 50 grams/square metre, more preferably be at least 70 grams/square metre.The basic weight that works the layer that reduces the delamination strength effect preferably is lower than 50% of the total basic weight of carpet underlay, more preferably less than 40% of the total basic weight of carpet underlay.
Though the delamination strength of end liner of the present invention is defined as above-mentioned with respect to not containing (replacement or extra) and can distinguishes for the end liner of layer, it is good that the delamination strength of measuring by DIN 54310 generally is lower than 6 Ns.
The invention still further relates to the carpet that comprises above-mentioned supatex fabric end liner.This carpet has high intensity and high elongation rate, and more even.
Above-mentioned tack temperature is meant (adhesive) polymer melt and/or softening, and the temperature of the formation bounding point that contacts between long filament or fiber.This tack temperature can be controlled by several different methods, for example reaches by the binder polymer of selecting to have different melting points and/or melt flow index or melt viscosity.
Melt temperature is to adopt well-known DSC (differential scanning calorimetry) technical measurement, wherein with the rate of heat addition heating of about 5 milligrams of samples (in blanket of nitrogen) with 10 ℃ of per minutes.Adopt the peak temperature of the melt endothermic curve that this DSC technology obtains in framework of the present invention, to be called as " melt temperature ".
Noun " recognizable " is though be meant that the long filament of different layers in supatex fabric or some mixing and/or the entanglement of fiber are that inevitably in fact the transition of its adjacent bed of course is not gradual change.Preferably, every layer all be basically uniformly (promptly in whole thickness, form and do not have big gradient) and/or every layer be to plant long filament or fiber or constitute by the long filament or the even blend of fiber of more than one types by single.
The reduction of binder polymer " concentration " can reach by distinct methods in the layer, for example hangs down the skin/core long filament or the fiber of skin/core ratio by employing, or reaches by blend a small amount of " the bonding long filament of using " or " binder fibre ".
Embodiment
All samples all adopt known technology that three layer filaments can be distinguished that layer successively is stacked and placed on the collector surface and forms through spunbond.In each sample, the basic weight of end liner be 120 the gram/square metre.Long filament is entirely to be core with the polyethylene terephthalate and to be the skin/core pattern of skin with the polyamide 6.Carry out heat bonding after placing sample on the gatherer.
Sample 1a and 1b (promptly in the same old way) are made of three layers of identical filament layer, every layer basic weight be 40 grams/square metre, the skin/core volume ratio that constitutes every layer long filament is 26/74, line density is 9 dtexs.(promptly according to the present invention) is made of two-layer identical skin and one deck internal layer sample 2a with 2b, and the skin/core volume ratio that wherein constitutes outer field long filament is 26/74, and the skin of internal layer/core volume ratio is 10/90.The line density of all long filaments is 9 dtexs, three layers basic weight all be 40 the gram/square metre.Sample 3 (also being according to the present invention) is to be made of two-layer identical skin and one deck internal layer, wherein each outer field basic weight be 36 the gram/square metre, skin/core volume the ratio that constitutes outer field long filament is 26/74, line density is 9 dtexs, and the basic weight of internal layer be 48 the gram/square metre, skin/core volume the ratio that constitutes the long filament of internal layer is 10/90, and line density is 6 dtexs.The tack temperature of preparation sample 1a and 2a prepares sample 1b, 2b and sample 3 is low.
Following performance to sample is measured: according to fracture strength and the elongation at break before the DIN 53857-2 mensuration synthetic tuft; According to fracture strength and the elongation at break behind the ASTM D2646 mensuration synthetic tuft; Measure delamination strength according to DIN 54310; And according to ten experts synthetic tuft sample outward appearance is given a mark, make evaluation with " evenly " or " inhomogeneous ".
Performance before table 1 synthetic tuft
Sample Intensity (MD/CMD)/2 (N/5cm) Percentage elongation (MD/CMD)/2 (%) Delamination strength (N)
The 1a contrast 334 22 7.4
The 1b contrast 324 22 11.6
2a the present invention 194 11 2.3
2b the present invention 203 12 4.0
3 the present invention 166 9 5.3
Performance behind table 2 synthetic tuft
Sample Intensity (MD/CMD)/2 (1bs) Percentage elongation (MD/CMD)/2 (%) Outward appearance
The 1a contrast 112 65 Inhomogeneous
The 1b contrast 105 64 Inhomogeneous
2a the present invention 138 76 Evenly
2b the present invention 136 72 Evenly
3 the present invention 144 73 Evenly
These experiments clearly illustrate that, though intensity and percentage elongation according to the present invention before the end liner synthetic tuft decrease and (see Table 1, relatively reduced about 35-60% with the contrast end liner), but behind synthetic tuft, still have quite high intensity and percentage elongation (see Table 2, relatively improved about 40%) with the contrast end liner.Simultaneously, the carpet also made with control sample of the outward appearance of the carpet made from the end liner according to the present invention is much even.

Claims (11)

1. one kind comprises through the bonding filament thermoplastic polymer of binder polymer or the non-woven carpet end liner of fiber, it is characterized in that this end liner comprises the recognizable thermoplasticity weaving layer of one deck at least, the recognizable thermoplasticity pantostrat of one deck or one deck also contain through the bonding filament thermoplastic polymer of binder polymer or the non-woven layer distinguished of fiber, this layer works to reduce the end liner delamination strength, the delamination strength of measuring according to DIN 54310 reduces at least 30% with respect to not containing the described similar end liner of layer of distinguishing, and the density of long filament or fiber is the 5-20 dtex.
2. the non-woven carpet end liner of claim 1, wherein said delamination strength reduces at least 50% with respect to not containing the described similar end liner of layer of distinguishing.
3. according to the non-woven carpet end liner of claim 1, wherein said play the layer that reduces the effect of end liner delamination strength be embedded in two comprise that distinguishing of filament thermoplastic polymer or fiber weaved and/or non-woven layer between, can distinguish layer thereby this non-woven carpet end liner comprises at least three layers.
4. according to the non-woven carpet end liner of claim 1, wherein said every layer all comprises by binder polymer through hot sticky filament thermoplastic polymer or fiber, wherein concentration and/or the tack temperature of binder polymer in working the layer that reduces the delamination strength effect is low by at least 20% than the binder polymer concentration in other layer, and/or than at least 4 ℃ of the tack temperature height of other layer.
5. according to the non-woven carpet end liner of claim 4, wherein concentration and/or the tack temperature of binder polymer in working the layer that reduces the delamination strength effect is low by at least 30% than the binder polymer concentration in other layer, and/or than at least 6 ℃ of the tack temperature height of other layer.
6. according to the non-woven carpet end liner of claim 1, wherein the binder polymer in the one deck at least in these layers constitutes the outer surface part of long filament or fiber at least.
7. according to the non-woven carpet end liner of claim 6, wherein long filament or fiber are skin/core pattern long filament or the fibers that forms skin with binder polymer.
8. according to any one non-woven carpet end liner of claim 1-7, wherein the binder polymer in the one deck at least in these layers is selected from one or more mixture of polyamide 6, copolyamide, polybutylene terephthalate (PBT), copolyester, polypropylene, co-polypropylene, polyethylene and these polymer.
9. according to any one non-woven carpet end liner of claim 1-7, the thermoplastic polymer that wherein constitutes in these layers long filament of one deck at least or fiber is selected from polyester, polyamide 6, polyamide 46, polyamide 66, copolyamide and copolyester.
10. according to any one non-woven carpet end liner of claim 1-7, its delamination strength is lower than 6 Ns.
11. comprise carpet according to any one non-woven carpet end liner of claim 1-10.
CNB998102121A 1998-08-27 1999-08-11 Nonwoven backing and carpet comprising same Expired - Fee Related CN1210458C (en)

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ATE294888T1 (en) 2005-05-15
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CA2341165A1 (en) 2000-03-09
US6207599B1 (en) 2001-03-27

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